Machine and process for assembling cathodes

ABSTRACT

Thin flat rectangular copper sheets and suspension bars are fed from opposite directions to a feed station. The sets, each comprising a sheet and bar, are moved alternately in opposite directions onto two assembly lines. Each set, while in horizontal position, is secured together by straps. The end of each assembly line has a table swingable from a horizontal position, in which it receives the assembly, to a vertical position on an axis parallel to the direction of movement of the assemblies. The table supporting surface comprises gate means which swing open to permit the assembly to be transferred onto slide rails which support the bar.

Jan. 23, 1973 United States Patent 1191 Kasper et al.

S T N E d T m m C S m E c T m A m w e R w W N U M H m S $E D C0 mm PA DC NG Am E um I M E m MA 4 U [75] Inventors: Cass Kaspencmsse Poime; veb 3,410,3s7 11 1968 Wennberg etal.................... .198/27 a Mount Clemens both of Priniary Examiner-Charles W. Lanham Assistant ExaminerDaniel C. Crane Attorney-Richard E. Dibner et al.

[73] Assignee: Inter-Lakes Engineering Co., Mount Clemens, Mich.

ABSTRACT Jan. 14, 1972 bars are fed from opposite directions to a feed station.

1211 Appl. No.: 217,782

The sets, each comprising a sheet and bar, are moved alternately in opposite directions onto two assembl lines. Each set,

while in horizontal position, is secured together by straps. The end of each assembly line has a table swingable from a horizontal position, in which it receives the assembly, to a vertical position on an axis parallel to the direction of movement of the assemblies. The table supporting surface comprises gate means which swing open to permit the assembly to be transferred onto slide rails which support the bar.

I 19 Claims, 8 Drawing Figures PATENTEDJAH 23 I975 SHEET 2 [1F 4 PATENTEDJAN 23 I975 SHEET 3 [IF 4 MACHINE AND PROCESS FOR ASSEMBLING CATHODES BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to the preparation of cathode assemblies such as those used in the electrolytic refinement of copper. These consist of thin sheets of pure copper which are to be placed between the anodes, the plates being suspended by bars secured to their upper edges.

2. Description of the Prior Art Wennberg et al US. Pat. No. 3,410,387 discloses an apparatus for handling these assemblies which includes a table swingable on an axis at right angles to the direction of movement of the assemblies. This apparatus has several disadvantages which it is an object of the present invention to overcome. In Wennberg, the table must swing up and then completely back down again before a cathode sheet assembly can be transferred whereas, according to the present invention, the assembly can be transferred as soon as the table swings up and only partially down, as will be later seen. Thus, other operations can take place during the time the table in the present invention is returning to its horizontal receiving position. Other advantages of the present invention over the Wennberg et al construction and the prior art described in said patent will become apparent from the following description.

BRIEF SUMMARY OF THE INVENTION The invention contemplates a method for assembling cathode sheets and suspension bars which comprises the steps of placing a horizontal sheet and bar in adjacent relation, simultaneously transporting the sheet and bar while horizontal in a direction parallel to the extent of the bar to an attaching station, attaching the bar to the sheet at the attaching station, transporting the assembly in the same direction while still in horizontal position to a rotating station, swinging the assembly on an axis parallel to said direction of movement so that said suspension bar is uppermost, and moving the vertical assembly by means of said bar along a path at right angles to said first direction of movement while maintaining the assembly in vertical position.

According to the illustrated embodiment of the invention, a dual assembly line extends in opposite directions from a central feed station toward which horizontal cathode sheets and suspension bars are fed from opposite directions. Successive sets, each comprising a cathode sheet and bar, are alternately moved in one direction and the other by transfer gate fingers. In effect, therefore, two assembly lines extend in opposite directions from the feed station, with each line having identical equipment for attaching the bars to the cathode sheets, rotating the assemblies to vertical position, and feeding them onto guide rails.

On each assembly line, the cathode sheet and bar first arrive at an attaching station where two straps are bent into looped form and fed around the bars and the adjacent edges of the cathode sheets. Dies secure the straps to the sheets by a piercing and clinching operation. The assembly is then fed onto a table of rectangular shape the bed of which comprises gate fingers swingable between a supporting position in the plane of the table and a releasing position away from said plane. The table is swingable on trunnions located between its edges so that it is partially counterbalanced. In its receiving position, the table is horizontal. After receiving an assembly, the table swings to a vertical position so that the suspension bar is engageable by a slidable carriage which moves at right angles to the original direction of movement of the assemblies. Upon swinging of the gate fingers to their open position and only partial return movement of the table, the carriage will convey the assembly onto slide rails. Transfer bars alongside these rails carry fingers which are rotatable into and out of transfer position with respect to the assemblies, the transfer bars reciprocating to move the assemblies along the rails.

The arrangement is highly efficient in terms of its production rate and has a space advantage with respect to previous constructions because of the double flow of assemblies and the change in direction of part flow when the assemblies leave the table. Only one transport means is needed for feeding both sheets and bars along the two assembly lines, reducing servicing problems. Because of the novel table construction the cycle time can be substantially increased.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic overall perspective view of the invention;

FIG. 2 is a fragmentary perspective view showing some of the conveyor fingers;

FIG. 3 is a schematic elevational view showing the paths of movement of the conveyor fingers;

FIG. 4 is a schematic end elevational view showing the movement of the fingers;

FIG. 5 is a partially schematic view showing the manner in which the straps are bent and clinched to the plates;

FIG. 6 is a perspective view of a table station with the table shown in its vertical position;

FIG. 7 is an end elevational view of the slide rails and transfer bars; and

FIG. 8 is a fragmentary side elevational view of the table shown in its horizontal position.

DESCRIPTION OF THE PREFERRED EMBODIMENT The entire apparatus is generally indicated at 11 and comprises two assembly lines 12 and 13 which are identical in construction but lead in opposite directions from a central feed station generally indicated at 14. Cathode sheets 15 are fed in succession from a feeder 16 which may include means for imparting a slight ribbing to the sheets to help maintain their flat condition. Cathode sheets 15 are of rectangular shape and in horizontal position when being fed from feeder 16.

Means indicated schematically by the arrow 17 are provided for feeding suspension bars 18 toward station 14 in the opposite direction from sheets 15. Bars 18 are somewhat longer than the edge of sheets 15 to which they will be attached so that the assembly may be suspended. The sheets 15 and bar 18 come to rest on rails 19 shown schematically in FIG. 2. Each set comprising a sheet and a bar is moved either to the left or to the right in FIG. 1 in alternate succession. This is done by a plurality of fingers 20 on each of three pairs of shafts 21, the shafts being rockable to move the fingers into and out of engagement with the bars and sheets, and also being axially movable in unison. Each pair of shafts 21 are axially aligned and are indicated at 21a and 21b in FIG. 1, having a connection 22 which permits relative rotation between them. As a set of fingers 20 on shafts 21a is moved downwardly at station 14 into engagement with the sheet and bar to move it to the right in FIG. 1, another set of fingers on shafts 21b is lifted out of engagement with the sheets and bars, in readiness to approach central station 14 simultaneously with the movement away from the station of the sheet and bar already there. The sets having been advanced along right hand assembly line 12, the fingers 20 on that line will be lifted by their shafts 21a out of engagement with the workpieces and fingers 20 along assembly line 13 and at station 14 will be lowered by shafts 21b. All the fingers with their shafts 21 will then move to the left, advancing the sets of workpieces along assembly line 13 while those on line 12 remain stationary. This will bring three fingers 20 on shafts 21a to station 14 where they will again be lowered while those along line 13 are raised, and all the fingers with their shafts will again move to the right, repeating the cycle. FIG. 3 illustrates some fingers 20 along line 13 and as viewed from the left in FIG. 1 with arrows indicating how the fingers will be lifted as they retract to the right and then are lowered to engage the workpieces for movement to the left. The shafts have supporting and activating means shown schematically at 23. In order to maintain the proper location of sheets 15 as they are moved along rails 19, canted rollers 24 are provided (FIG. 4) which contact the sheets and urge them against stops 25.

Each assembly section 12 and 13 has a bar attaching station generally indicated at 26 in FIG. 1 at which each set comprising a sheet and a bar arrives after leaving station 14. Straps 27'are stored in two stacks at the station. These piles are carried in magazines (FIG. having means for lifting the pile to a constant level. Above each pile are a pair of suction cups 28 on vertically-movable rods 29 riding in a pusher 30 (FIG. 5). The suction cups will lift the topmost straps and pushers 30 will move to the left, carrying the straps to be deposited at a bending location adjacent laterally retractable mandrels 31 and bending tools 32. After pushers 30 and their suction cups retract to the right, the mandrels will be extended over the straps and bending tools 32 will move upwardly and around the mandrel to bend the straps into loops 33. Mandrels 31 will then be retracted. When pushers 30 again move to the left with the next set of straps, they will push loops 33 to the left around bar 18 until the ends of the loop overlap sheet 15. Thus, each reciprocation of pushers 30 will result in a pair of looped straps being advanced into position for attachment to a sheet 15, and also deliver a pair of unbent straps at the bending location.

Looped straps 33 will be attached by upper dies 34 and lower dies 35 which squeeze the loops together. Piercing dies 36 will penetrate the loop ends and sheet so that portions of the sheet may be bent into gripping relation with the loops by clinching dies 37. It should be noted that this method of securing strap loops 33 to sheet will leave no pockets or voids which could harbor acid or other contaminants.

The assembly 38 comprising two straps, a bar 18 and a plate 15 is then advanced by fingers 20 to a rotating station generally indicated at 39 where it is moved from horizontal to vertical position as shown in FIG. 1. At this station is a table generally indicated at 41 (FIGS. 6 and 8). The table is of rectangular configuration, having a U-shaped frame 42. A pair of trunnions in the form of stub shafts 43 extend from intermediate portions of the legs of frame42 and are supported by a framework 44 of the machine. The axis of trunnions 43 is parallel to and to one side of the direction of movement of assemblies 38. The trunnions permit tilting of the table from a horizontal position as shown in FIG. 8 to a vertical position shown in FIG. 6. In the horizontal position, the table is at the same level as assemblies 38 leaving station 24 (FIG. 6) so as to receive the assembly as advanced by fingers 20. The means for rotating table 41 comprises a reciprocable fluid motor 45 the piston rod 46 of which is pivotally connected at 47 to the table.

The table face is formed by a plurality of fingers 48 pivotally mounted with respect to frame 42 by a pair of shafts 49 extending along the legs of the U-shaped frame. Also mounted on these shafts are stops 50 for locating assemblies 38. These fingers and stops are swingable by cylinders 51 connected by cranks 52 to shafts 49 between a receiving position as shown in solid lines in FIG. 6 and a discharge position as shown in dotdash lines. The receiving position will be assumed when the table is horizontal as in FIG. 8 so that the assembly 38 will be smoothly received from station 24. Retaining members 53 will then be advanced into position beneath the ends of bar 18 (FIG. 8) by cylinders 54, these cylinders being carried by the table and connected to the retaining members by bell cranks 55. Table 41 will then be swung to a vertical position as shown in FIG. 6, assembly 38 being kept from slipping off the table by members 53. As the table reaches its vertical position, the outer portions of bar 18 will be caught and retained by a pair of hooks 56 on a carriage 57; this carriage is slidably mounted on rods 58 supported by frame 44 and movable at right angles to the original direction of movement of assemblies 38. After table 41 has partially descended so that its upper portions are out of the path of movement of bar 18, carriage 57 will advance assembly 38 through the open gate formed by fingers 48 and stops 50 onto a pair of slide rails 59. There they will be retained by pivotal catches 60 and stopped by the first of fingers 61 carried by a pair of transfer bars 62 alongside rails 59. These bars are supported by rollers 63 which permit both sliding and rotating movement.

As seen in FIG. 7, fingers 61 are movable between an upper position shown in dot-dash lines and lower positions shown in solid lines. After an assembly 38 is moved by carriage 57 onto rails 59 and bar 18 engages the first fingers 61, which are in their upper position at that time, the fingers will swing down to their lower positions and transfer bars 62 will move to the left in FIG. 6 (out of the paper in FIG. 7) a distance equal to the spacing between assemblies 38 on the rails. The spacing could for example be one inch. Fingers 61 will then be rotated into their upright positions and transfer bars 62 move to the right in FIG. 6 (into the paper in FIG. 7). This will advance all the assemblies 38 on slide rails 59, and the parts will be in readiness to receive the next assembly 38 from table 41.

it will be observed that the advancing of each assembly 38 from table 41 to the slide rails may be accomplished while the table is returning to its horizontal position in readiness for receiving the next assembly 38 from station 24. Thus, the rate of transfer of assemblies 38 may be quite rapid.

To summarize the operation, a first sheet and bar 18 will reach station 14 and will be advanced by fingers 20, say, to the right in FIG. 1 along assembly line 12 to station 26. The next set comprising a sheet 15 and bar 18 will be moved to the left in FIG. 1 so that alternate sets will be sent onto assembly sections 12 and 13 respectively. At stations 26, straps 27 will be bent into loops 33 and fed onto bars 18 and sheets 15 where they will be secured by dies 34 and 35. The assemblies 38 will then be advanced onto tables 41 while the latter are in horizontal position. Each table will swing to its vertical position and bar 18 will be engaged by hooks 56. The gates comprising fingers 48 and stops 50 will swing open and carriage 57 advanced to carry assembly 38 onto guide rails 59 until they are stopped by the first fingers 61. The fingers carried by transfer bars 62 will then be rotated into retracted position, the transfer bars moved to the left in FIG. 8, the fingers rotated upwardly again, and all the assemblies 38 on guide rails 59 advanced one increment. While this is taking place, fingers 48 and stops 50 will swing back to their sheet supporting position and table 41 swung back to its horizontal position to receive the next assembly.

We claim:

1. In a machine for assembling cathode sheets and suspension bars, a feed station, means delivering said sheets and bars in a horizontal position toward said feed station, means transporting successive sets each comprising a sheet and a bar while in said horizontal position in a direction parallel to the extent of said bar to an attaching station, means at said attaching station securing the bar to the sheet to form an assembly, means transporting said assembly to a table swingable on an axis parallel to said direction of movement between a receiving position in said horizontal plane and a vertical discharge position, and a carriage engageable with the bar of each assembly when said table is swung to its discharge position, said carriage being movable at right angles to the original direction of movement of said assembly to carry the assembly while vertical away from said table.

2. The combination according to claim 1, the transporting means for said sets comprising fingers engageable with the edges of said sheets and bars, and means for retracting said fingers from engaging position and returning them to engage the next set.

3. The combination according to claim 2, further comprising a guide for the edges of said sheets adjacent said bars, and rollers supporting said sheets and inclined toward said bars, whereby the sheet edges will be constantly urged against said guides as they are pushed by said fingers.

4. The combination according to claim 1, said means for attaching the bar to the sheet comprising a plurality of flat straps, means transporting said straps to a bending station, means bending said straps into a looped shape at the bending station, and means feeding the straps from the bending station around the bar so that their ends overlap the sheet.

5. The combination according to claim 4, further provided with piercing and clinching dies on opposite sides of said sheet engageable with the straps to secure them to the sheet.

6. The combination according to claim 4, said means for moving the flat straps and feeding the bent straps onto the bars comprising a reciprocable pusher movable in a horizontal direction and a plurality of suction cup members carried by said pusher and movable in a vertical direction.

7. The combination according to claim 1, said table having support means for said assemblies when in receiving position, said support means being swingable into non-obstructing relation with the assembly after the table swings to its discharge position, whereby said carriage may transport the vertical assemblies past said support means.

8. The combination according to claim 7, said support means comprising a plurality of fingers mounted along the opposite edges of said table and movable between a position in the plane of the table and an open position permitting the assembly to pass therebetween.

9. The combination according to claim 1, further provided with a pair of rails extending from said table and receiving the assembly pushed by said carriage, and a pair of transfer bars alongside said rails, said transfer bars being axially reciprocable and having fingers rotatable into and out of engaging relation with the assemblies on said rails, said transfer bars being movable in synchronism with said carriage to move the assemblies along said rails.

10. The combination according to claim 9, further provided with retainers movably mounted adjacent the entrances of said rails and engageable with suspension bars initially placed thereon to prevent said bars from moving backward on the rails.

11. The combination according to claim 1, further provided with retaining means carried by said table and movable between a retracted position and a position adjacent said bar to prevent the assembly from slipping from said table when it is tilted to its discharge position.

12. In a machine for assembling cathode sheets and suspension bars, a feed station, means transporting sheets toward said feed station from one direction and suspension bars from the opposite direction, said sheets,

and bars being in horizontal position, a pair of assembly lines extending in opposite directions from said feed station parallel to the extent of said bars, means transporting successive sets each comprising a sheet and a bar alternately in opposite directions along said two assembly lines, an attaching station on each of said assembly lines, means at said attaching station securing said bar to said sheet while they are still in said horizontal plane, two rotating stations outwardly of said attaching stations in the same direction of movement, each rotating station having a table movable between a receiving position in said horizontal plane and a vertical position, said movement being on an axis parallel to the direction of movement of the assemblies, a carriage at each of said tilting stations engageable with each assembly when moved to its vertical position to carry the assembly while in vertical position away from the rotating stations in a direction at right angles to the original semblies along said guide rails and maintaining them in equally spaced relation.

13. The combination according to claim 12, said means for transporting the assemblies along said assembly lines comprising shafts extending along the assembly lines and movable both axially and rotationally, the shafts moving axially in unison first in one direction and then in the opposite direction, the fingers on the shafts for one assembly line being engageable with the work-pieces by rotation of their shafts when the shafts move axially in one direction and the fingers for the other line being engageable with the workpieces when the shafts move axially in the opposite direction, whereby fingers from alternate assembly lines will be brought to the feed station and then be moved to workengaging positions.

14. The combination according to claim 12, the means at each attaching station for securing the bar to the sheet comprising a plurality of flat straps, pickup means engageable with the uppermost straps and movable to lift them to the level of the sheet and bar, said pickup means being carried by a pusher, and means bending said straps into loops, said pusher moving the bent straps around said bar and sheet while its pickup means carries flat straps into position to be bent by said bending means.

15. The combination according to claim 12, said table comprising a U-shaped frame having a pair of trunnions intermediate its ends so that the table is partially counterbalanced, the axis of said trunnions being to one side of the path of movement of said horizontal assemblies, supporting means for said assemblies on said table comprising a pair of swinging gates hinged along the opposite edges of said table, and means moving said gates between a supporting position in the plane of said table when it is horizontal and an open position when the table is vertical permitting the car riage to move the assembly therethrough.

16. The combination according to claim 15, said gates being of finger-like construction.

17. The combination according to claim 15, further provided with retractable means carried by said table and disposed adjacent said bar when the table moves to its vertical position to prevent the assembly from sliding off the table.

18. The combination according to claim 17, said carriage being slidable on a pair of rails and having hookshaped members engageable with the bars of said assemblies.

19. The combination according to claim 15, said table being further provided with stops for locating said assemblies, said stops being hinged with said gates along the opposite edges of said table. 

1. In a machine for assembling cathode sheets and suspension bars, a feed station, means delivering said sheets and bars in a horizontal position toward said feed station, means transporting successive sets each comprising a sheet and a bar while in said horizontal position in a direction parallel to the extent of said bar to an attaching station, means at said attaching station securing the bar to the sheet to form an assembly, means transporting said assembly to a table swingable on an axis parallel to said direction of movement between a receiving position in said horizontal plane and a vertical discharge position, and a carriage engageable with the bar of each assembly when said table is swung to its discharge position, said carriage being movable at right angles to the original direction of movement of said assembly to carry the assembly while vertical away from said table.
 2. The combination according to claim 1, the transporting means for said sets comprising fingers engageable with the edges of said sheets and bars, and means for retracting said fingers from engaging position and returning them to engage the next set.
 3. The combination according to claim 2, further comprising a guide for the edges of said sheets adjacent said bars, and rollers supporting said sheets and inclined toward said bars, whereby the sheet edges will be constantly urged against said guides as they are pushed by said fingers.
 4. The combination according to claim 1, said means for attaching the bar to the sheet comprising a plurality of flat straps, means transporting said straps to a bending station, means bending said straps into a looped shape at the bending station, and means feeding the straps from the bending station around the bar so that their ends overlap the sheet.
 5. The combination according to claim 4, further provided with piercing and clinching dies on opposite sides of said sheet engageable with the straps to secure them to the sheet.
 6. The combination according to claim 4, said means for moving the flat straps and feeding the bent straps onto the bars comprising a reciprocable pusher movable in a horizontal direction and a plurality of suction cup members carried by said pusher and movable in a vertical direction.
 7. The combination according to claim 1, said table having support means for said assemblies when in receiving position, said support means being swingable into non-obstructing relation with the assembly after the table swings to its discharge position, whereby said carriage may transport the vertical assemblies past said support means.
 8. The combination according to claim 7, said support means comprising a plurality of fingers mounted along the opposite edges of said table and movable between a position in the plane of the table and an open position permitting the assembly to pass therebetween.
 9. The combination according to claim 1, further provided with a pair of rails extending from said table and receiving the assembly pushed by said carriage, and a pair of transfer bars alongside said rails, said transfer bars being axially reciprocable and having fingers rotatable into and out of engaging relation with the assemblies on said rails, said transfer bars being movable in synchronism with said carriage to move the assemblies along said rails.
 10. The combination according to claim 9, further provided with retainers movably mounted adjacent the entrances of said rails and engageable with suspension bars initially placed thereon to prevent said bars from moving backward on the rails.
 11. The combination according to claim 1, further provided with retaining means carried by said table and movable between a retracted position and a posItion adjacent said bar to prevent the assembly from slipping from said table when it is tilted to its discharge position.
 12. In a machine for assembling cathode sheets and suspension bars, a feed station, means transporting sheets toward said feed station from one direction and suspension bars from the opposite direction, said sheets and bars being in horizontal position, a pair of assembly lines extending in opposite directions from said feed station parallel to the extent of said bars, means transporting successive sets each comprising a sheet and a bar alternately in opposite directions along said two assembly lines, an attaching station on each of said assembly lines, means at said attaching station securing said bar to said sheet while they are still in said horizontal plane, two rotating stations outwardly of said attaching stations in the same direction of movement, each rotating station having a table movable between a receiving position in said horizontal plane and a vertical position, said movement being on an axis parallel to the direction of movement of the assemblies, a carriage at each of said tilting stations engageable with each assembly when moved to its vertical position to carry the assembly while in vertical position away from the rotating stations in a direction at right angles to the original direction of movement, guide rails receiving said assemblies from said carriages and supporting them by said bars in vertical position, and means moving said assemblies along said guide rails and maintaining them in equally spaced relation.
 13. The combination according to claim 12, said means for transporting the assemblies along said assembly lines comprising shafts extending along the assembly lines and movable both axially and rotationally, the shafts moving axially in unison first in one direction and then in the opposite direction, the fingers on the shafts for one assembly line being engageable with the work-pieces by rotation of their shafts when the shafts move axially in one direction and the fingers for the other line being engageable with the workpieces when the shafts move axially in the opposite direction, whereby fingers from alternate assembly lines will be brought to the feed station and then be moved to work-engaging positions.
 14. The combination according to claim 12, the means at each attaching station for securing the bar to the sheet comprising a plurality of flat straps, pickup means engageable with the uppermost straps and movable to lift them to the level of the sheet and bar, said pickup means being carried by a pusher, and means bending said straps into loops, said pusher moving the bent straps around said bar and sheet while its pickup means carries flat straps into position to be bent by said bending means.
 15. The combination according to claim 12, said table comprising a U-shaped frame having a pair of trunnions intermediate its ends so that the table is partially counterbalanced, the axis of said trunnions being to one side of the path of movement of said horizontal assemblies, supporting means for said assemblies on said table comprising a pair of swinging gates hinged along the opposite edges of said table, and means moving said gates between a supporting position in the plane of said table when it is horizontal and an open position when the table is vertical permitting the carriage to move the assembly therethrough.
 16. The combination according to claim 15, said gates being of finger-like construction.
 17. The combination according to claim 15, further provided with retractable means carried by said table and disposed adjacent said bar when the table moves to its vertical position to prevent the assembly from sliding off the table.
 18. The combination according to claim 17, said carriage being slidable on a pair of rails and having hook-shaped members engageable with the bars of said assemblies.
 19. The combination according to claim 15, said table being further provided with stops for locating said aSsemblies, said stops being hinged with said gates along the opposite edges of said table. 